EP3433902B1 - Connector equipped with a cooling element - Google Patents

Description

The invention relates to a connector part for connection to a mating connector part according to the preamble of claim 1.

Such a plug connector part comprises a contact element for making electrical contact with an associated mating contact element of the mating connector part. The contact element has a contact section for making contact with the mating contact element of the mating connector part and a shaft section for connecting a load line for transmitting an electrical current.

Such a connector part can be used in particular as a charging plug or as a charging socket for charging an electrically powered vehicle (also referred to as an electric vehicle). In this case, for example, a cable is connected on the one hand to a charging station and on the other hand carries the connector part in the form of a charging plug, which can be plugged into an associated mating connector part in the form of a charging socket on a vehicle in order to establish an electrical connection between the charging station and the Vehicle manufacture.

Charging currents can basically be transmitted as direct currents or as alternating currents, whereby in particular charging currents in the form of direct current have a high current strength, for example greater than 200 A or even greater than 300 A or even 350 A, and cause the cable to heat up just like one with the Cable connected connector part can lead.

One from the DE 10 2010 007 975 B4 The known charging cable has a coolant line which comprises a supply line and a return line for a coolant and thus enables a coolant flow to and from the charging cable. The coolant line of the DE 10 2010 007 975 B4 serves here on the one hand to dissipate the heat loss occurring in an energy store of a vehicle, but also to cool the cable itself. The WO 2009/134379 A1 describes a charging plug that is connected to a charging station via a cable. A cooling system is provided for this. The WO 2012/051510 A2 discloses a connector that can be connected to a mating connector, a cooling channel being formed in each of the two housing halves so that the coolant can flow in a flow direction from the mating connector into the connector.

In a charging system for charging an electric vehicle, heat is generated not only on the cable with which a charging plug is connected, for example, to a charging station, but also on the charging plug and in particular inside the charging plug for example on contact elements via which an electrical contact with associated mating contact elements is established, for example on the side of a charging socket on an electric vehicle, when the charging plug is inserted into the charging socket. Such contact elements, which are made of an electrically conductive metal material, for example a copper material, heat up when a charging current flows over the contact elements, whereby the contact elements are basically to be dimensioned depending on the charging current to be transmitted so that the contact elements have a sufficient Have current carrying capacity and heating at the contact elements is limited. The rule here is that a contact element must be dimensioned larger, the larger the charging current to be transmitted.

However, there are limits to scaling the contact element size with increasing charging current due to the associated space requirements, weight and costs. There is therefore a need to transmit a large charging current with a contact element of comparatively small dimensions.

With one from the WO 2015/119791 A1 known charging system for charging an electric vehicle are guided within a charging cable coolant lines, via which heat can also be dissipated from the area of a connector part connected to the charging cable.

With one from the U.S. 8,835,782 known contact element, cooling fins are arranged on a shaft of the contact element.

The object of the present invention is to provide a plug connector part with a contact element which can have a high current carrying capacity, for example for use in a charging system for charging an electric vehicle.

This object is achieved by an object having the features of claim 1.

Accordingly, the connector part has a channel extending in the contact element, with which at least one coolant line can be flow-connected, for guiding a coolant through the contact element.

By providing the channel in the contact element, a coolant can be passed directly through the contact element. This creates a cooling immediately provided where heat is generated during operation of the connector part when an electrical current is passed through the contact element.

If the connector part is designed as a charging plug, for example, and if a load line for transmitting a charging current, for example a direct current, is connected to the contact element, the contact element is heated during a charging process. Because a coolant can be passed through the channel of the contact element, this heat can be absorbed by the contact element and dissipated by the contact element, which makes it possible to dimension the contact element comparatively small with a high current carrying capacity.

The contact element is preferably made of metal and has a one-piece body which forms the contact section, for example in the form of a contact socket or a contact piece, and the shaft section. The channel is molded into this one-piece body, for example by making a bore in the body. The channel thus extends within the body, so that a coolant can be conducted through the body and thus a heating of the body can be counteracted.

The contact element can, for example, have an essentially cylindrical basic shape. Correspondingly, the shaft section via which a load line is to be connected to the contact element can also be shaped cylindrically so that a load line can, for example, be inserted into the shaft section or attached to the shaft section in order to make electrical contact with the contact element.

In this case, the channel can for example be extended coaxially to the shaft section, so that the channel extends axially in the contact element and thus a coolant can flow longitudinally through the contact element.

The channel provides a closed guide for the coolant, so that the coolant can be introduced into the channel via a coolant line that is flow-connected to the channel and can be discharged from the channel via another coolant line that is flow-connected to the channel. A coolant flow is thus provided through the channel, by means of which heat can be absorbed at the contact element and can be dissipated in a guided manner.

The channel can for example have a first end, with which a first coolant line can be flow-connected, and a second end, with which a second coolant line can be flow-connected. The channel is designed to guide a coolant between the first end and the second end, so that a flow path is provided within the contact element by means of the channel and a coolant can thus flow through the contact element.

To connect the first coolant line, the contact element can, for example, have an attachment stub which extends radially inside the shaft section. The attachment socket can for example be coaxial with the shaft section, the shaft section e.g. forms a hollow cylinder and the coolant line can be inserted into an interspace between the radially outer shaft section and the radially inner attachment stub, in order to produce a flow connection between the coolant line and the channel extending inside the attachment stub.

A coolant can, for example, be supplied via the first coolant line connected to the attachment socket. This first coolant line can extend, for example, within an electrically conductive line jacket of the load line, so that the coolant line is routed within the load line and can thus also absorb heat on the load line. To connect the load line with the coolant line guided therein to the contact element, the line jacket of the load line is, for example, pushed onto the shaft section of the contact element and, for example, pressed with the shaft section via a sleeve element. The coolant line, on the other hand, is attached to the attachment stub and is connected in flow to the channel extending in the contact element.

In order to provide a coolant circuit, a connection element is preferably attached to the contact element, which is flow-connected to the channel and to which the second coolant line can be connected. The second coolant line can serve, for example, to divert the coolant, so that a coolant circuit is provided by supplying the coolant via the first coolant line and by diverting the coolant via the second coolant line.

The connecting element can be made of plastic or metal. The connecting element can, for example, have the shape of an L-piece, with a flow channel molded into it, which connects to the channel of the contact element There is a flow connection and thus enables the coolant to be discharged from the channel.

In one embodiment, the connector part is connected to a cable in which a load line connected to the contact element and at least one coolant line are routed. If the connector part is designed as a charging plug, for example, the cable can establish a connection with a charging station, for example, so that the connector part with an associated mating connector part, for example in the form of a charging socket, can be plugged into an electric vehicle in order to establish an electrical connection between the Charging station and the electric vehicle to charge batteries of the electric vehicle.

In one embodiment, the load line can have an electrically conductive line jacket, within which a coolant line is routed. The cable sheath can be implemented, for example, by a braided copper wire (or copper wire) and is used to transmit the load current. Because a coolant line extends coaxially inside the line jacket, heat can be absorbed directly on the load line via coolant flowing in the coolant line in order to at least reduce heating along the load line. Because a coolant flows through the coolant line laid within the load line and also a contact element connected to the load line, cooling can be provided both on the load line and on the contact element connected to the load line.

The cable sheath can for example be plugged onto the shaft section of the contact element, so that the cable jacket at least partially surrounds the shaft section circumferentially. The cable sheath is thus electrically contacted with the shaft section, it being possible for the connection to be secured, for example, via a sleeve element that is pressed with the shaft section.

While the line sheath of the load line is plugged onto the shaft section, the coolant line guided in the line sheath of the load line is preferably attached to a radially inner connection piece coaxial with the shank section and in this way connected to the contact element. The coolant line is flow-connected to the channel extending in the contact element via the attachment nozzle, so that a coolant can flow into the channel via the coolant line.

In order to provide a coolant circuit, a further coolant line is preferably guided in the cable, which extends outside the load line and is thus laid separately from the load line in the cable. This further coolant line is also connected to the contact element and is in flow connection with the channel so that a coolant, for example, can be diverted from the channel of the contact element via this additional coolant line.

A coolant used for cooling can be, for example, gaseous or liquid. For example, an air flow can be provided for cooling, which is introduced into the duct and discharged from the duct, in order in this way to provide a cooling circuit.

A plug connector part of the type described here can be used, for example, as a charging plug or socket in a charging system for charging an electric vehicle. Such a connector part can for example be arranged on a charging cable and connected to a charging station via the charging cable. A charging plug of this type can be plugged into a charging socket on the side of an electric vehicle, for example, in order to transfer charging currents between the charging station and the electric vehicle.

Fig. 1

eine Ansicht eines Ladesystems zum Aufladen eines Elektrofahrzeugs;

Fig. 2

eine Ansicht eines Steckverbinderteils in Form eines Ladesteckers;

Fig. 3

eine Ansicht einer zwei Kontaktelemente umfassenden Unterbaugruppe des Steckverbinderteils;

Fig. 4

eine gesonderte Ansicht der Kontaktelemente;

Fig. 5

eine gesonderte Explosionsansicht eines Kontaktelements;

Fig. 6

eine Schnittansicht entlang der Linie A-A gemäß Fig. 5; und

Fig. 7

eine andere Schnittansicht entlang der Linie A-A gemäß Fig. 5.

The idea on which the invention is based will be explained in more detail below with reference to the exemplary embodiments shown in the figures. Show it:

Fig. 1

a view of a charging system for charging an electric vehicle;

Fig. 2

a view of a connector part in the form of a charging plug;

Fig. 3

a view of a subassembly of the connector part comprising two contact elements;

Fig. 4

a separate view of the contact elements;

Fig. 5

a separate exploded view of a contact element;

Fig. 6

a sectional view along the line AA according to Fig. 5 ; and

Fig. 7

another sectional view along the line AA according to FIG Fig. 5 .

Fig. 1 shows a charging station 1, which is used to charge an electrically powered vehicle 4, also referred to as an electric vehicle. The charging station 1 is designed to provide a charging current in the form of an alternating current or a direct current and has a cable 2, which at one end 201 with the charging station 1 and at the other end 200 with a connector part 3 in the form of a charging plug connected is.

As shown in the enlarged view Fig. 2 As can be seen, the plug connector part 3 on a housing 30 has plug-in sections 300, 301, with which the plug connector part 3 can be brought into engagement with an associated mating plug connector part 40 in the form of a charging socket on the vehicle 4. In this way, the charging station 1 can be electrically connected to the vehicle 4 in order to transmit charging currents from the charging station 1 to the vehicle 4.

In order to quickly charge the electric vehicle 4 e.g. In the context of a so-called fast charging process, the transferred charging currents have a high current strength, e.g. greater than 200 A, possibly even on the order of 350 A or more. Due to such high charging currents, thermal losses occur on the cable 2 and also on the connector part 3 and the charging socket 40, which can lead to the cable 2, the connector part 3 and the charging socket 40 heating up.

The plug connector part 3 has a plurality of contact elements on its plug-in sections 300, 301. For example, two contact elements for transmitting a charging current in the form of a direct current can be arranged on the plug-in section 301, while contact elements for providing a grounding PE contact and signal contacts for transmitting control signals can be arranged on the plug-in section 300, for example.

Fig. 3 shows an embodiment of a subassembly of the connector part 3, with a housing part 302 on which the plug-in sections 300, 301 are formed. On the housing part 302, among other things, two contact elements 31, 32 are arranged which are provided with contact sections 310, 320 (see FIG Fig. 4 ) protrude into the lower plug section 301 and form the plug face which, when the plug connector part 3 is plugged into the associated mating connector part 40 with mating contact elements 400 of the mating connector part 40 (see FIG Fig. 1 ) can make electrical contact. So get the Contact sections 310, 320 of contact elements 31, 32 designed as contact sockets engage with mating contact elements 400 designed as contact pins when plug connector part 3 is inserted into mating connector part 40, so that electrical contact is established between contact elements 31, 32 and mating contact elements 400.

The in Figures 4 to 7 The illustrated exemplary embodiment of the contact elements 31, 32 is connected to the contact elements 31, 32 with load lines 21, 22 guided in the cable 2. These load lines 21, 22 are used to transmit an electrical (direct) current between the charging station 1 and the electric vehicle 4 and each have an electrically conductive cable sheath 210, 220 sheathed by electrical insulation, for example in the form of a braided copper wire, which is attached to a shaft section 312 of the associated contact element 31, 32 is attached and in this way electrically contacted with the contact element 31, 32.

For the mechanically firm connection of the cable jacket 210, 220 to the shaft section 312, a cylindrical sleeve element 314 made of metal is attached to the shaft section 312 in such a way that the cable jacket 210, 220 pushed onto the shaft section 312 is press-connected to the shaft section 312 via the sleeve element 314 is. The sleeve element 114 can in this case, after being attached to the shaft section 312, be pressed with the shaft section 312 using a suitable pressing device with the cable jacket 210, 220 interposed.

A coolant line 23, 24 is routed inside the line jacket 210, 220 and is thus received and routed coaxially within the load line 21, 22. In this way, heat can be absorbed directly on the load line 21, 22 via a coolant flowing through the coolant line 23, 24 and removed from the load line 21, 22 in order to prevent (excessive) heating of the load line 21, 42 along the lines extending in the cable 2 Avoid length.

As in Figures 5 to 7 For the contact element 31 shown, the coolant line 23, 24 of each contact element 31, 32 is attached to an attachment socket 313 arranged radially inside the cylindrical shaft section 312 by inserting the coolant line 23, 24 into a circumferential space formed between the attachment socket 313 and the shaft section 312 319 is plugged in. In this way, the coolant line 23, 24 is connected to an inside of the attachment socket 313 extending channel 317 of the contact element 31, 32 flow-connected, so that a coolant can flow between the coolant line 23, 24 and the channel 317.

The contact elements 31, 32 have an essentially cylindrical basic shape, with a longitudinal axis L forming the cylinder axis. Along this longitudinal axis L, the contact elements 31, 32 can be inserted into engagement with the associated mating contact elements 400, and the load lines close along this longitudinal axis L 21, 22 to the contact elements 31, 32.

The contact element 31, 32 is formed in one piece as a metal body and has a cylinder section 311 adjoining the contact section 310, 320, from which the shaft section 312 protrudes axially. The channel 317 is formed in the contact element 31, 32, coaxially to the cylindrical shaft section 312 and to the cylinder section 311, for example in the form of a bore, and extends within the contact element 31, 32. By means of a coolant flowing through the channel 317, heat can thus accumulate the contact element 31, 32 and removed from the contact element 31, 32.

A connecting element 315 in the form of an L-piece is attached to the cylinder section 311 and has a flow channel 318 which is in flow connection with the channel 317 molded into the contact element 31, 32. A further coolant line 25, 26 is attached to an attachment stub 316 formed on the connecting element 315, so that this further coolant line 25, 26 is also in flow connection with the channel 317 and thus a coolant circuit can be provided.

For example, as in Figures 6 and 7 shown, a coolant is supplied via the coolant line 23, 24 laid coaxially within the load line 21, 22 and thus flows into the channel 317 in a flow direction F1. The coolant flows out of the channel 317 via the connecting element 315 and is diverted via the coolant line 25, 26 in a flow direction F2, so that a coolant flow through the contact element 31, 32 results.

Via this coolant flow, heat is absorbed both on the load line 21, 22 and on the contact element 31, 32 connected to the load line 21, 22. For example, a gaseous fluid, for example air, can be used as the coolant it is also conceivable and possible to use an (electrically non-conductive) coolant liquid.

While the coolant lines 23, 24 are laid coaxially within the load lines 21, 22 electrically connected to the contact elements 31, 32, the coolant lines 25, 26, which are connected to the connecting elements 315 of the contact elements 31, 32, extend outside the load lines 21, 22. Both the load lines 21, 22 with the coolant lines 23, 24 routed therein and the further coolant lines 25, 26 are laid within the cable 2 and thus extend from the charging station 1 to the connector part 3.

The idea on which the invention is based is not restricted to the exemplary embodiments described above, but can in principle also be implemented with completely different types of embodiments.

A connector part of the type described here can be used in the context of a charging system for charging an electric vehicle. However, it is also conceivable and possible to use a plug connector part of the type described here in other applications for plugging connection with an associated mating connector part.

Because a channel for conducting a coolant is introduced directly into a contact element, cooling is provided directly on the contact element. Heat can thus be effectively absorbed at the contact element and dissipated from the contact element.

Because a coolant line is also extended within a load line, heat can also be effectively absorbed on the load line. Because the coolant line extends coaxially within the load line, the coolant line lies on the inside over a large area against a current-carrying line jacket of the load line, so that heat can be effectively introduced into the coolant line and a coolant guided therein.

Although a cooling of contact elements serving for the transmission of direct current has been described above, this is not restrictive. In principle, cooling of the type described here can also be used on contact elements that are used to transmit an alternating current.

List of reference symbols

1

Charging station

2

Charging cable

200, 201

The End

21, 22

Load line

210, 220

Electrically conductive cable sheath

23-26

Coolant line

3

Charging plug

30th

casing

300, 301

Plug section

302

Housing part

31, 32

Contact element (load contact)

310, 320

Contact section (socket)

311

Cylinder section

312

Shaft section

313

Attachment socket

314

Sleeve element

315

Connecting element

316

Attachment socket

317

channel

318

channel

319

Space

4th

vehicle

40

Charging socket

400

Mating contact element

F1, F2

Flow direction

L.

Longitudinal axis

Claims (10)

1. Plug connector part (3) for connection to a mating plug connector part (40), comprising

   - a contact element (31, 32) for making electrical contact with an associated mating contact element (400) of the mating plug connector part (40), wherein the contact element (31, 32) has a contact section (310) for making contact with the mating contact element (400) of the mating plug connector part (40) and has a shaft section (312) for connection of a load line (21, 22) for transmitting an electric current, and

   - a duct (317), which extends in the contact element (31, 32) and to which at least one coolant line (23-26) can be connected in terms of flow, for carrying a coolant through the contact element (31, 32),

   wherein the duct (317) has a first end, to which a first coolant line (23, 24) can be connected in terms of flow, and a second end, to which a second coolant line (25, 26) can be connected in terms of flow, wherein the duct is designed to carry a coolant between the first end and the second end, wherein the coolant is supplied via the first coolant line (23, 24), which is laid coaxially within the load line (21, 22), and flows into the duct (317) in a flow direction (F1), and wherein the coolant flows out of the duct (317) via a connecting element (315) and is discharged via the second coolant line (25, 26) in a flow direction (F2), so that a coolant flow is produced through the contact element (31, 32),
   characterized in that the connecting element (315), which is connected in terms of flow to the duct (317) and to which the second coolant line (25, 26) can be connected, is fitted on the contact element (31, 32), wherein the connecting element (315) is in the form of an L-shaped piece with a flow duct integrally formed therein, which flow duct is connected in terms of flow to the duct (317) of the contact element (31, 32) and allows the coolant to be discharged from the duct (317).
2. Plug connector part (3) according to Claim 1, characterized in that the contact element (31, 32) has a one-piece body which forms the contact section (310) and the shaft section (312) and in which the duct (317) is integrally formed.
3. Plug connector part (3) according to Claim 1 or 2, characterized in that the shaft section (312) is formed in a cylindrical manner.
4. Plug connector part (3) according to Claim 3, characterized in that the duct (317) extends coaxially in relation to the shaft section (312).
5. Plug connector part (3) according to one of Claims 1 to 4, characterized in that the contact element (31, 32) has a fitting port (313) which extends radially within the shaft section (312) and to which the first coolant line (23, 24) can be connected to form a connection in terms of flow with the duct (317).
6. Assembly characterized by a plug connector part (3) according to one of the preceding claims and a cable (2) which is connected to the plug connector part (3) and guides a load line (21, 22), which is connected to the contact element (31, 32), and at least one coolant line (23-26).
7. Assembly according to Claim 6, characterized in that the load line (21, 22) has an electrically conductive line sheath (210) and a coolant line (23, 24) is guided coaxially within the line sheath (210).
8. Assembly according to Claim 7, characterized in that the line sheath (210) is mounted onto the shaft section (312) of the contact element (31, 32) in such a way that the line sheath (210) at least partially surrounds the circumference of the shaft section (312).
9. Assembly according to Claim 7 or 8, characterized in that the coolant line (23, 24) which is guided coaxially within the line sheath (210) is connected to the contact element (31, 32) in such a way that the coolant line (23, 24) is connected in terms of flow to the duct (317) of the contact element (31, 32).
10. Assembly according to one of Claims 7 to 9, characterized in that a further coolant line (25, 26) is guided in the cable (2), which further coolant line extends outside the load line (21, 22) and is connected to the contact element (31, 32) in such a way that the second coolant line (25, 26) is connected in terms of flow to the duct (317).

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